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Composites Use In Heavy Truck Ed Zenk Ed Zenk Composite Materials Engineer, International Truck & Engine Corp. Composite Materials Engineer, International.

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Presentation on theme: "Composites Use In Heavy Truck Ed Zenk Ed Zenk Composite Materials Engineer, International Truck & Engine Corp. Composite Materials Engineer, International."— Presentation transcript:

1 Composites Use In Heavy Truck Ed Zenk Ed Zenk Composite Materials Engineer, International Truck & Engine Corp. Composite Materials Engineer, International Truck & Engine Corp.

2 Current Materials Spray-up/lay-up Spray-up/lay-up Cold mold Cold mold SMC SMC RTM RTM

3 Parts Using Composites Roofs Roofs Hoods Hoods Fairings Fairings Doors Doors Bumpers Bumpers Reinforcements Reinforcements

4 Differences with automotive Larger parts Larger parts Severe service applications Severe service applications Lower volumes Lower volumes Cosmetics (colors, surfaces) Cosmetics (colors, surfaces)

5 New Materials/Process LPSMC LPSMC UV Cured materials UV Cured materials Advanced Composites (Carbon fiber) Advanced Composites (Carbon fiber) Dicyclopentadiene (DCPD) Dicyclopentadiene (DCPD)

6 New Applications Frames Frames Cabs Cabs Under-the-hood Under-the-hood

7 Advantages Balanced Mechanical Properties Low Temperature Impact to –40°F Excellent Dimensional Stability -20°F to 175°F Nonmoisture Absorbing Outstanding Surface Replication and Paint Adhesion 98+ D.O.I. 5B Crosshatch Index Standard Two Component Urethane Light Weight – 1.03 gm/cc Low Pressure Processing Large, Complex Part Capability Numerous Tooling Options Low Cost Short Lead Time Liquid Molded DCPD for Heavy Truck

8 Mechanical Properties Property ASTM Method Value Density, g/cm 3 (lbs/in 3 )D7921.03 (0.037) 24 Hr. Water AbsorptionD5700.12% Tensile Modulus, GPa (Ksi)D6381.90 (275) Tensile Strength @ yield, MPa (Ksi)D63846.8 (6.8) Flexural Modulus, GPa (Ksi)D7901.88 (273) Flexural Strength @ 5% strain, MPa (Ksi)D79070 (10.1) Yield StrainD6384.7% Rockwell HardnessD785R114 Notched Izod Impact, J/m (ft-lb/in) @ 23  C (73.4  F) @-40  C (-40  F) D256460 (8.7) 106 (2.0) Compression Strength, MPa (Ksi)D69558.4 (8.5) Shear Strength, MPa (Ksi)D73249.5 (7.2) DTUL @ 264 psi,  C (  F) D648108 (226) (3) Glass Transition Temperature,  C (  F) DMA (4) >138 (>280) Coefficient of Thermal Expansion, m/m/  C (in/in/  F) D69687.8x10 -6 (48.8x10 -6 ) Dielectric Constant 60Hz @ 73  F D1502.66 Dissipation Factor 60Hz @ 73  F D1500.0006 Shrinkage in/in (mm/mm) 0.009 Poisson’s Ratio ( ) 0.39 Flame Class Rating (5) ULHB

9 Manufacturing Improvements 90-95% FTQ vs. 60-70% on previous version 90-95% FTQ vs. 60-70% on previous version Average of 1.5 passes through paint versus 2.5 to 3 passes for previous version Average of 1.5 passes through paint versus 2.5 to 3 passes for previous version Greatly reduced prep time in plant prior to paint Greatly reduced prep time in plant prior to paint

10 Cost-1997 DCPD was 90.0% of HSU hood in piece price DCPD was 90.0% of HSU hood in piece price 61.3% increase in tooling cost 61.3% increase in tooling cost Payback achieved in the fourth year Payback achieved in the fourth year Annual Volume 3000 units Annual Volume 3000 units

11 Cost-2000 DCPD was 70.0% of HSU hood in piece price DCPD was 70.0% of HSU hood in piece price 105.6% increase in tooling cost 105.6% increase in tooling cost Payback achieved in second year Payback achieved in second year Annual volume 6000 units Annual volume 6000 units

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